2005-2009 Suzuki VL 1500 Intruder, Boulevard, C90, C90T Service Manual (P/N 99500-38040)

• Official 100-page Suzuki factory publication (P/N 99500-38040) for 1998–2009 VL 1500 Intruder and Boulevard C90/C90T models.
• Details the V-twin SOHC engine and shaft drive configurations across the K1 through K9 supplements.
• Includes over 50 detailed exploded-view mechanical diagrams and specific torque-value assembly tables.

Mechanical and Systems Documentation

This factory reference provides structured technical data for the entire Intruder and Boulevard C90 lineup. It outlines precise periodic maintenance intervals for components like spark plugs, fuel strainers, and engine oil. You get specific mechanical guidance for the shaft drive and cooling systems. Every major subsystem is covered. The manual details engine removal, chassis maintenance, electrical system pinouts, and the exact emission control components required for E-03, E-28, and E-33 regional configurations.

Specification and Reference Highlights

Inside, you will find the critical technical data necessary for accurate shop work. Torque values are clearly mapped, including the 160 N·m (115.5 lb-ft) generator rotor bolt specification and the 37 N·m (27.0 lb-ft) final torque for cylinder head bolts. It documents engine oil capacity at 5.0 liters for a complete overhaul, with the fuel tank holding 15.5 liters. Standard compression pressure readings sit between 1,000 and 1,400 kPa (142–199 psi). Please note that these specifications are intended for professional reference. Always ensure standard workshop safety protocols are followed and consult a certified technician before performing complex service operations on this equipment.